Abstract: The present invention relates to sulfur tolerant catalyst composites useful for reducing contaminants in exhaust gas streams, especially gaseous streams containing sulfur oxide contaminants. More specifically, the present invention is concerned with improved NOx trap catalysts for use in diesel engines as well as lean burn gasoline engines. The sulfur tolerant NOx trap catalyst composites comprise a platinum component, a support, and a NOx sorbent component prepared by hydrothermal synthesis. The NOx sorbent component comprises a first metal oxide and a second metal oxide. The metal in the first metal oxide is selected from the group consisting of aluminum, titanium, zirconium, silicon, and composites thereof, and the metal in the second metal oxide is selected from the group consisting of Group IIA metals, Group II metals, Group IV metals, rare earth metals, and transition metals. The metal in the first metal oxide is different from the metal in the second metal oxide.

Abstract: The present invention relates to sulfur tolerant catalyst composites useful for reducing contaminants in exhaust gas streams, especially gaseous streams containing sulfur oxide contaminants. More specifically, the present invention is concerned with improved NOx trap catalysts for use in diesel engines as well as lean burn gasoline engines. The sulfur tolerant NOx trap catalyst composites comprise a platinum component, a support, and a NOx sorbent component prepared by hydrothermal synthesis. The NOx sorbent component comprises a first metal oxide and a second metal oxide. The metal in the first metal oxide is selected from the group consisting of aluminum, titanium, zirconium, silicon, and composites thereof, and the metal in the second metal oxide is selected from the group consisting of Group IIA metals, Group III metals, Group IV metals, rare earth metals, and transition metals. The metal in the first metal oxide is different from the metal in the second metal oxide.

Abstract: The present invention is directed to a catalyzed metallic substrate, such as a metal plate. There is a catalyst layer supported on the substrate surface. The article is useful as part of exhaust systems which can be used with small engines for applications such as motorcycles, lawn mowers, chain saws, weed trimmers and the like. The present invention includes methods to prepare the catalyzed metal substrate and methods of use of the catalyzed substrate.

Abstract: Electric arc spraying a metal onto a substrate produces an anchor layer on the substrate that serves as a surprisingly superior intermediate layer for a catalytic material deposited thereon. Spalling of catalytic material is resisted even when subjected to the harsh conditions imposed by small engines or in a close-coupled position for a larger engine.

Abstract: A catalyst reduction system using diesel fuel as a reductant for vehicles equipped with diesel engines reduces NOx transient emissions produced during acceleration. Impending engine accelerations are sensed to produce metered pulse(s) of fuel oil simultaneously with and preferably in advance of, the NOx transient emission. The fuel pulse is sufficient in quantity to reduce the NOx transient emission when the NOx and HC resulting from the cracked fuel oil are present at spatially equal distances within the reducing catalytic converter. Optionally, the washcoat of the reducing catalyst is formulated to delay the adsorption/desorbtion of one of the gases on the washcoat to assure proper timing of the NOx transient and fuel pulse(s).

Abstract: A pollutant treating device especially adapted for motor vehicles in which a housing containing a catalyst composition for treating pollutants is positioned within the normal flow pattern of ambient air within the motor vehicle and is preferably removably placed within a support, such as a bracket assembly where the housing can be readily removed and replaced and/or reused.

Abstract: A catalyst reduction system using diesel fuel as a reductant for vehicles equipped with diesel engines reduces NOx transient emissions produced during acceleration. Impending engine accelerations are sensed to produce metered pulse(s) of fuel oil simultaneously with and preferably in advance of, the NOx transient emission. The fuel pulse is sufficient in quantity to reduce the NOx transient emission when the NOx and HC resulting from the cracked fuel oil are present at spatially equal distances within the reducing catalytic converter. Optionally, the washcoat of the reducing catalyst is formulated to delay the adsorption/desorbtion of one of the gases on the washcoat to assure proper timing of the NOx transient and fuel pulse(s).

Abstract: A pollutant treating device especially adapted for motor vehicles in which a housing containing a catalyst composition for treating pollutants is positioned within the normal flow pattern of ambient air within the motor vehicle and is preferably removably placed within a support, such as a bracket assembly where the housing can be readily removed and replaced and/or reused.

Abstract: A catalyst reduction system using diesel fuel as a reductant for vehicles equipped with diesel engines reduces NOx transient emissions produced during acceleration. Impending engine accelerations are sensed to produce metered pulse(s) of fuel oil simultaneously with and preferably in advance of, the NOx transient emission. The fuel pulse is sufficient in quantity to reduce the NOx transient emission when the NOx and HC resulting from the cracked fuel oil are present at spatially equal distances within the reducing catalytic converter. Optionally, the washcoat of the reducing catalyst is formulated to delay the adsorption/desorbtion of one of the gases on the washcoat to assure proper timing of the NOx transient and fuel pulse(s).

Abstract: Electric arc spraying a metal onto a substrate produces an anchor layer on the substrate that serves as a surprisingly superior intermediate layer for a catalytic material deposited thereon. Spalling of catalytic material is resisted even when subjected to the harsh conditions imposed by small engines or in a close-coupled position for a larger engine.

Abstract: The present invention is directed to a substrate, such as a honeycomb having a plurality of parallel channels defined by the honeycomb walls. The honeycomb has different zones along the length of the channels. The zones are defined by their coating (or lack of coating) and extend for a length of the channel in which there is the same coating and architecture. Soluble components in coating compositions are fixed in their respective zones.

Abstract: A catalyst composition and structure containing the same and methods for treating diesel exhaust including a catalyst comprising a precious metal on a support, a first zeolite component in the presence of a precious metal and a second zeolite component comprising a zeolite and a precious metal, and a non-catalytic pore-containing zeolite.

Abstract: Method of catalytically activating the surface of a heat exchange device while retaining the heat exchange properties of the device and heat exchange devices obtained thereby.

Abstract: A catalyst composition contains a catalytic material having having an undercoat layer containing a mixture of a fine particulate undercoat refractory metal oxide and a sol such as a silica sol, the undercoat providing good adherence to substrates, such as metal substrates, on which the catalytic material is disposed. An overlayer is coated over the underlayer and contains an overlayer refractory metal oxide, which may be the same as or different from the undercoat refractory metal oxide, and on which is dispersed one or more catalytic metal components, such as palladium and manganese components. The metal substrate may be made of, e.g., aluminum or titanium or alloys thereof, and provides a low pressure drop and lightweight catalyst, making the catalyst especially well adapted for use in aircraft to abate ozone in cabin air.

Abstract: The present invention relates to a layered catalyst composite of the type generally referred to as a three-way conversion catalyst having the capability of substantially simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides. The structure of the layered catalyst composite of the present invention is designed wherein there is a first layer and a second layer. The first layer comprises a first support; at least one first palladium component and an oxygen storage component in intimate contact with the palladium component; optionally another first platinum group metal component; a zirconium component; at least one first alkaline earth metal components and at least one first rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components.

Abstract: A catalyst composition contains a catalytic material having having an undercoat layer containing a mixture of a fine particulate undercoat refractory metal oxide and a sol such as a silica sol, the undercoat providing good adherence to substrates, such as metal substrates, on which the catalytic material is disposed. An overlayer is coated over the underlayer and contains an overlayer refractory metal oxide, which may be the same as or different from the undercoat refractory metal oxide, and on which is dispersed one or more catalytic metal components, such as palladium and manganese components. The metal substrate may be made of, e.g., aluminum or titanium or alloys thereof, and provides a low pressure drop and lightweight catalyst, making the catalyst especially well adapted for use in aircraft to abate ozone in cabin air.

Abstract: A method of improving the performance of a pollutant abatement means, e.g., catalytic converter (16), used to purify engine exhaust gas streams and the like includes combusting a combustion mixture of air and a low ignition temperature fuel in the exhaust gas stream upstream of the catalytic converter (16) to oxidize carbon monoxide and unburned hydrocarbons, and/or to rapidly heat the catalytic converter to its operating temperature. Reaction conditions are maintained so as to cause the combustion mixture to ignite spontaneously. A control system may be used to regulate the supply of the combustion mixture in response to time lapse or temperature of the catalyst or both. The apparatus includes a fuel supply (18) and a fuel line (20) controlled by a valve (22) to deliver a low ignition temperature fuel into the exhaust gas discharge line (14) associated with the engine (12). An air pump (26) provides combustion air through an air line (28) into the exhaust gas discharge line (14).

Abstract: A method for controlling exhaust gas emissions from an engine (16) includes extracting a light distillate fuel (Fd) from conventional gasoline or other liquid hydrocarbon fuel and supplying the engine with the light distillate fuel during an initial operation period of the engine. This reduces the oxidizable pollutants in the engine exhaust during a cold-start period before a catalytic converter (22) used to abate pollutants in the engine exhaust gases has not yet attained its operating temperature. After the catalytic converter (22) has been sufficiently heated, the fuel supply to the engine (16) is switched to gasoline or other liquid hydrocarbon fuel. Both the distillate fuel (Fd) and the liquid hydrocarbon fuel may be passed through a heated cracking catalyst bed (30) to crack the fuel fed to the engine.

Abstract: A catalyst composition includes a carrier on which is disposed a catalytic material which may optionally be provided in discrete first and second coats. The catalyst material contains, e.g., in the first coat, a refractory inorganic oxide first support having a catalytically effective amount of platinum dispersed thereon. The catalyst material also contains, e.g., in the second coat, a stabilized alumina second support having a catalytically effective amount of a second platinum catalyst dispersed thereon, and a third catalyst component which contains a zirconia-stabilized third support, e.g., alumina, having dispersed thereon catalytically effective amounts of rhodium and palladium. A method of treating internal combustion engine exhaust gases with the catalyst composition is also disclosed.

Abstract: H.sub.2 S formation by three-way catalyst is suppressed by incorporating nickel, manganese or iron oxides into an undercoat layer disposed on a substrate, such as a monolith substrate. A topcoat overlying the undercoat is comprised of a three-way catalyst material which includes one or more of platinum, rhodium and palladium as catalytic metals.